Mixing method and system

ABSTRACT

A mixing method and system for the thorough intermixing of liquids of widely different viscosities in which there is interposed at least one perforated plate in the line of flow ahead of a conventional static mixer.

CROSS REFERENCE TO RELATED APPLICATION

The subject matter of this Application relates to the invention of Application Ser. No. 306,921, filed Nov. 15, 1972, now U.S. Pat. No. 3,861,652, of common assignment.

BRIEF SUMMARY OF THE INVENTION

Generally, this invention comprises a mixing method and system for liquids of widely different viscosities incorporating one or more perforated plates interposed in the line of flow of the liquids during their supply under pressure to conventional mixing apparatus of static design.

DRAWINGS

The following drawings detail a preferred embodiment of the invention and the physical principles of operation, wherein:

FIG. 1 is a partially schematic longitudinal sectional view of a preferred embodiment of apparatus constructed according to this invention for the mixing of two liquids of widely different viscosities in which three perforated plates in series were utilized in conjunction with a plurality of static mixer elements,

FIG. 2 is a plan view of a preferred design of perforated plate for the apparatus of FIG. 1,

FIGS. 3 and 4 are plan views of second and third alternative designs of perforated plates utilized as elements for the apparatus of FIGS. 1 and 2 to obtain an operational comparison with the FIG. 2 plate design, and

FIGS. 5-10, inclusive, are plan views of additional designs of perforated plates which were all tested and found to be of varying effectiveness as hereinafter reported.

DETAILED DESCRIPTION

Continuous mixing of widely different viscosity liquids, and gases with liquids, is difficult to achieve. A wide variety of dynamic (power-driven) mixers have been employed in this service, including multiple-blade turbines, multistage helical ribbon designs, torpedo designs, and two-shaft, wiped surface mixers. Such mixers are relatively expensive and, for very intimate mix uniformities, require lengthy periods of operation and high power consumption.

Recently, various designs of static mixers have become available commercially, these including warped deflection plate types such as those disclosed in Armeniades et al. U.S. Pat. No. 3,286,992 and Potter U.S. Pat. No. 3,635,444, which operate by successive stream division followed by a folding recombination of ingredients. The static mixers are less expensive in first and operational costs but they, too, have been less than completely effective, especially unless used in large numbers in series flow circuit.

I have now discovered that very substantial mixing advantages can be obtained by interposing one or more perforated plates in series flow disposition with respect to the fluids to be mixed while they are fed under pressure to static mixing apparatus.

Referring to FIG. 1, a preferred embodiment of system according to my invention, utilizing static mixer elements of the general design taught in U.S. Pat. Nos. 3,286,992 and 3,635,444 supra, comprises a tubular flow conduit 10 which is supplied at entrance and 10a with the high viscosity liquid to be mixed from a pump or other pressure source not shown. The low viscosity liquid component is supplied under pressure through a line 11 terminating in a discharge outlet 11a oriented generally axially of conduit 10 with its vent opening downstream of the flow of high viscosity liquid.

In the system of FIG. 1 three perforated plate elements 12a, 12b and 12c are utilized in series arrangement spaced approximately one conduit 10 diameter apart, with the first perforated plate, 12a, disposed approximately 0.5 to 2.0 conduit 10 diameters downstream from the vent 11a of conduit 11. For convenience in mounting the perforated plates 12a, 12b and 12c, flanged sections of conduit were assembled in prolongation one with another as shown in FIG. 1 to provide the continuous flow conduit 10 in the plate region.

Deferring description of the plate perforation details until later, the static mixer elements disposed in seriatim one with another and with perforated plates 12a, 12b and 12c consist of 20 to 30 warped plate pairs 15a, 15b to 15n, 15n', alternate members of each pair having opposite directions of twist, mounted fixedly in place within conduit 10 with the entrance end of the first static mixer pair preferably spaced not more than about 10 conduit 10 diameters downstream from the last perforated plate element 12c. After traversing the last plate pair, 15n, 15n', the intimately combined liquid mixture discharges from the system via outlet 10b.

Turning now to FIG. 2, an actual design of perforated plate element 12, which in this instance was a 1inch diameter perforated area size (surrounded by an annular flange section of 2 inch outside diameter), consisted of a 1/8inch thick steel plate provided with 85 holes 13 each 0.07 inch in diameter spaced uniformly at center-to-center distances of 0.100 inch ±0.017 inch taken parallel with respect to lines inclined 60° counter-clockwise from the horizontal and 0.0867 inch ±0.015 inch taken normally with respect to lines drawn 60° counter-clockwise with respect to the horizontal. The twelve holes denoted 14 were each approximately tangent to the inside wall of conduit 10 which, for the design portrayed, had a 1 inch inside diameter.

A less preferred alternate design of perforated plate 12' is detailed in FIG. 3, wherein the construction is generally the same as for FIG. 2, consisting again of a 1/8inch thick steel plate provided, in this instance, with 43 holes 13', 0.07 inch diameter, distributed in alternate rows along the ordinate at 0.134 inch hole-to-hole vertical spacing and at 60° inclination 0.116 inch ±0.020 inch spacing. Six holes 14' were disposed tangent to the inside wall of the conduit 10 which, for this design, also was 1 inch inside diameter.

An oversize perforated plate 12 inches is detailed in FIG. 4, this being a 2 inch diameter perforated area (4 inches outside diameter flange size) 1/8 inch thick steel plate provided with 241 drilled holes, each 0.07 inch diameter, spaced 0.120 inch between hole centers and 0.104 inch ±0.01 inch between adjacent parallel rows of hole centers the six holes denoted 14 inches being tangent to the supply conduit 10 which, in this instance, was 2 inches inside diameter. This perforated plate was provided immediately downstream with a 4 inch transition length conventional pipe reducer, not shown, constricting the flow to 1 inch prior to introduction into static mixers 15a, 15b - 15n, 15n' for the comparative performance tests hereinafter reported.

Additional designs of perforated plates (of thicknesses reported in TABLE I) had hole dispositions and sizes as indicated in FIGS. 5-10, respectively, as to which all perforated area diameters were 1 inch diameter, some plates being of 2 inches outside diameter flange design, whereas others were secured, in place in the flow conduit by cementing around the peripheries, none of this detail being further provided because it has no bearing on the operation of the perforated plates.

The mixing action of apparatus constructed according to this invention, using glass conduits 10 permitting visual observation of the mixing obtained, appears to be as follows: Perforated plates 12, 12' and 12" divide the single stream of low viscosity liquid into many smaller streams and thus greatly increase the interfacial area between the low and high viscosity liquids. Downstream of each perforated plate 12 there is created a multiplicity of wakes in which the pressure is lower than that in the liquid more remote from these wakes. The low viscosity liquid preferentially accumulates in the flow wakes and, moreover, the lower viscosity liquid appears to be able to move laterally across the higher viscosity liquid streamlines within the wakes. The lower viscosity liquid leaves the wakes in sheets or threads where streamlines of high viscosity liquid meet again downstream of the wakes.

From the foregoing, it will be understood that perforated plates 12 provide preliminary break-up, subdivision and distribution of low viscosity liquids in high viscosity liquids. Completion of the mixing of the liquids to obtain a uniform effluent, when they are miscible or soluble, is dependent on molecular diffusion plus the action of subsequent mixing devices such as the static laminar mixers hereinafter described.

My tests have revealed the following:

1. The plan view shapes of holes 13, 13', 13" can be widely varied: circular, square, triangular, hexagonal and other configurations being all operable; however, circular holes are preferred because of ease of fabrication.

2. Hole diameters can be anywhere in the range of about 1/4 to 1/100 of the conduit 10 diameter; however, 1/8 to 1/32 is preferred.

3. The ratio of total cross-sectional area of all holes 13, 13', 13" divided by the cross-sectional area of conduit 10 can be from about 1/20 to about 3/4, but 1/3 to 1/2 is preferred.

4. The number of plates 12 utilized can range from one to about ten, with two to four being preferred.

5. Plates 12 can be disposed all upstream of the mixers, or they can be interspersed between successive mixer elements, such as the ones denoted 15a, 15b - 15n, 15n', FIG. 1. If the plates 12 are located upstream from the mixers, the spacing between adjacent plates should be in the range of about 1/4 to about 10 conduit 10 diameters, with 1-3 diameters being preferred.

6. The supply of lower viscosity liquid to be mixed can be via one or more holes in a conventional distributor ring, but a single injection tube such as that detailed at 11, 11a, FIG. 1, is preferred.

7. The distance between the lower viscosity liquid injection point and the first downstream perforated plate 12 should be in the range of about 1/8 to 10 or more conduit 10 diameters, with 1/2 to 2 diameters preferred.

8. Mixing according to this invention is effective where the proportion of low viscosity liquid to be mixed with high viscosity liquid is in the volumetric flow ratio range of about 0.01 to 0.2, and where the ratio of viscosities of high viscosity liquid to low viscosity liquid is in the range of about 4 × 10³ to 10⁶.

A vertically oriented test apparatus was constructed generally resembling that shown in FIG. 1. Corn syrup (Corn Products Co. Code 1132) was utilized as the high viscosity liquid to be blended, this material having a viscosity of 1050 poises at 20° C. and 450 poises at 30° C. Water dyed with 0.5 gm of methylene blue for each 5 gallons volume was utilized as the low viscosity liquid.

The corn syrup was stored in a 30 gal. Binks tank under air pressure, which could be adjusted to vary the corn syrup flow rate. The syrup was supplied to the apparatus via an 18 inch long horizontal 1 inch dia. pipe, thence through a pipe tee and vertically upwards for 12 inches of 1 inch dia. pipe to the first perforated plate 12.

The dyed water was stored in a 5 ga. Binks tank under air pressure. A rotameter and needle valve were used to adjust and measure the water flow rate. Water was injected into the syrup through a 1/8 inch outside diameter, 1/16 inch inside diameter tube pointed upwards (i.e., downstream) near the center of the syrup flow pipe 10. The point of water injection was 1 inch to 2 inches upstream of the first perforated plate 12. After the sixteenth test tabulated in the following TABLE III, i.e., after Test 2-7-14, the feed tanks were wrapped with 1/4 inch tubing for circulation of constant temperature water, and then encased in insulation.

Perforated plates 12, disposed transverse conduit 10, were followed downstream by static spiral mixers of the Kenics Static® design, which generally resembled those disclosed in U.S. Pat. No. 3,286,992 supra, arranged in series sequence up conduit 10. Four, four-element edgesealed Kenics® modules were employed in most of the mixing tests herein reported. The mixer elements were fabricated from stainless steel, whereas conduit 10 was 1 inch i.d. glass.

The effluent flow rate discharged from outlet 10b was determined by weighing the effluent for a measured period of time.

The characteristics of the perforated plates 12 utilized are given in TABLE I, with typical hole arrangements shown in FIGS. 2-10, inclusive. The characteristics of any screens employed in supplementation are given in TABLE II.

                                      TABLE I                                      __________________________________________________________________________     PERFORATED PLATE DIMENSIONS                                                    __________________________________________________________________________     Hole diameter, in.                                                                       1/4 3/16                                                                               1/8 3/32                                                                               1/16                                                                               0.070                                                                              0.070 0.070                                                                              0.070                              Drawing FIGURE                                                                           5   7   8   9   10  3   not shown                                                                            2   4                                  Number of holes                                                                          3   7   19  19  19  43  61    85  241                                Plate diam.*, in.                                                                        1   1   1   1   1   1   1     1   2                                  Fraction open area                                                                       0.19                                                                               0.25                                                                               0.30                                                                               0.17                                                                               0.07                                                                               0.21                                                                               0.30  0.44                                                                               0.30                               Thickness, in.                                                                           1/8 1/8 1/8 1/8 1/8 0.04                                                                               0.04  0.04                                                                               1/8                                __________________________________________________________________________      *Diameter of circle tangent to outer holes.                              

                  TABLE II                                                         ______________________________________                                         WIRE SCREENS                                                                   ______________________________________                                         Mesh          35       60       150    270                                     Wire diameter, in.                                                                         0.012    0.009    0.0026 0.0016                                    Weave       Plain    Plain    Plain  Twill                                     Opening, in.                                                                               0.017    0.008    0.004  0.002                                     Fraction open area                                                                         0.34     0.21     0.37   0.32                                      ______________________________________                                    

                                      TABLE III                                    __________________________________________________________________________                      Syrup         Effluent                                                                               Total                                                    Temp (° C.)                                                                     Per Cent                                                                             Rate (lbs/hr)                                                                          Apparatus                               Test             Viscosity,                                                                             Water in                                                                             Viscosity,                                                                             Pressure Drop, ΔP,                No.  Equipment   poises  Effluent                                                                             poises  p.s.i.     Observations                 __________________________________________________________________________     1-6-30                                                                              20 Kenics.sup.®                                                                        (31)    0.6   (42)    --         A few 1/16"                       Mixer elements                                                                             385           --                 water globules                    in a 1" glass                                were observed                     pipe.                                        in the effluent.                  No perforated                                                                  plates.                                                                   2-6-30                                                                               "                  2.1   (47)                                                                           --      21         1/8"-1/4" water                                                                globules in the                                                                effluent.                    1-7-3                                                                               In series, in 1"                                                                           (31)    9.8   (42.7)  10         A few 1/8" water                  glass pipe: 385           12                 globules were                     A perforated plate                           observed after                    thick provided                               10 Kenics.sup.®               with 3-1/4" holes                            elements, but                     (FIG. 5) + 4                                 mostly striations.                Kenics.sup.®  elements +                 No water globules                 a perforated plate                           and only a few                    with 7 1/8" holes                            trace striations                  (FIG. 6) + 4                                 observed after                    Kenics.sup.®  elements +                 20 Kenics.sup.®               a perforated plate                           elements.                         with 19 1/8" holes                                                             (FIG. 8) + 12                                                                  Kenics.sup.®  elements.                                               2-7-3                                                                               In series, in 1"                                                                           (31)    2.5   (41.4)  14.5       No water globules                 glass pipe: 385           94                 and very attenuated               A perforated plate                           striations observed               1/8" thick provided                          after 14                                                                       Kenics.sup.®                  with 3-1/4" holes                            elements. No stria-               (FIG. 5) + 4                                 tions seen after 20               Kenics.sup.®  elements +                 Kenics.sup.®                                                               elements.                         a perforated plate                                                             with 7 1/8" holes                                                              (FIG. 6) + 4                                                                   Kenics.sup.®  elements +                                                   a perforated plate                                                             with 19 1/8" holes                                                             (FIG. 8) + 12                                                                  Kenics.sup.®  elements.                                               1-7-5                                                                               In series in a 1"   15.3  (27.5)  48         Water spread across               glass pipe:                                  all of down stream                One perforated plate                         side of plate.                    thick, provided with                         Channeling was ob-                19 1/16" (FIG. 10)                           served thru first 8               holes + 16 Kenics®                       Kenics.sup.®                                                               elements.                         elements.                                    Water globules re-                                                             formed. Extreme                                                                striations and water                                                           globules after 16                                                              elements.                    2-7-5                                                                               In series in        15    (27)    48         Same as Test                      a 1" glass pipe:                             #1-7-5, except that               One perforated                               water globules did                plate 1/8" thick pro-                        not reform.                       vided with 19 1/16"                                                            (FIG. 10) holes + 4                                                            Kenics.sup.®  elements +                                                   one perforated                                                                 plate with 19 1/8"                                                             holes (FIG. 8) +                                                               12 Kenics.sup.®                                                            elements.                                                                 1-7-7                                                                               In series in a      10    (42)    19         Same observations                 1" glass pipe:                               as Test 1-7-5.                    Three perforated                                                               plates having (1)                                                              3 1/4" holes (FIG.                                                             5), (2) 7 3/16" holes                                                          (FIG. 7), (3) 19                                                               1/8" holes (FIG. 8)                                                            + 16 Kenics®                                                               elements.                                                                 1-7-11                                                                              4 Perforated                                                                               400 (ap-                                                                               8.1   (51.6)  13         Water layer seen                  plates each hav-                                                                               prox.)                       downstream of                     ing 19 1/8"                                  each plate.                       holes (FIG. 8),                              Channeling occurred               plates spaced 1"                             after first 4                     apart + 16                                   Kenics.sup.®                                                               elements.                         Kenics.sup.®                             No channeling in                  elements.                                    9th-12th elements.                                                             Weak striations ob-                                                            served after 12th                                                              element.                     2-7-11                                                                               "          400 (ap-                                                                               2.2   (48.5)  16         No segregated water                               prox.)    150                seen after 4th                                                                 plate. No channeling                                                           in Kenics.sup.®                                                            ele-                                                                           ments. No stria-                                                               tions observed after                                                           8th element.                 3-7-11                                                                              Same apparatus                                                                             (26)    2.4   (43.3)  17         Same observations                 as Test 1-7-11,                                                                            400 (ap-      177                as Test 2-7-11.                   except that 3/32"                                                                              prox.)                                                         holes (FIG. 9) were                                                            substituted.                                                              4-7-11                                                                              Same apparatus                                                                             400 (ap-                                                                               8.4   (50.2)  12         No channeling in                  as Test 1-7-11, prox.)    22                 Kenics.sup.®                                                               elements.                         except that 3/32"                            Very weak stria-                  holes (FIG. 9)                               tions observed - were                                                          substituted.      after                                                        12th element.                1-7-12                                                                               "          (26)    8.8   (47.5)  16         Same observations                             400 (ap-      24                 as Test 4-7-11.                                   prox.)                                                    2-7-12                                                                               "          (27)    9.6   (23.4)  9          Same observations                             400 (ap-      20                 as Test 4-7-11,                                   prox.)                       except that syrup                                                              fragments were de-                                                             tected in 12th ele-                                                            ment effluent.               1-7-13                                                                              Same apparatus                                                                             (26)    9.2   (45.8)  13         1/8" water layer ob-              as Test 3-7-11,                                                                            400 (ap-      25                 served on back-                   except that 61  prox.)                       sides of 3rd and 4th              0.07" holes were                             plates. There was                 substituted.                                 some channeling in                                                             first 4                                                                        Kenics.sup.®                                                               elements. 1/32"-1/16"                                                          syrup fragments ob-                                                            served after 12                                                                elements.                    1-7-14                                                                              Same apparatus                                                                             (25)    2.3   (45.7)  19         1/16" water                       as Test 3-7-11,                                                                            400 (ap-      138                layer on third                    except that 61  prox.)                       plate but none                    0.07" holes were                             on fourth.                        substituted.                                 No channeling                                                                  in Kenics.sup.®                                                            elements. No                                                                   syrup frag-                                                                    ments after                                                                    12 elements.                 2-7-14                                                                              Same apparatus                                                                             400 (ap-                                                                               2.3   (46.5)  15         No water on                       as Test 1-7-14, prox.)                       first plate,                      except that per-                             <1/8" on                          forated plates                               third and none                    were spaced                                  on fourth. No                     6" apart.                                    channeling in                                                                  Kenics.sup.®  ele-                                                         ments. No                                                                      striations or                                                                  syrup fragments                                                                after 8th                                                                      element.                     1a-8-3                                                                              Four plates (20)    7.8   (25.4)  9          Water layers on                   with 19 1/8"                                                                               1046          27                 4 plates.                         holes in each                                Channeling after                  (FIG. 8)                                     4th plate and for                 followed by 16                               4 Kenics.sup.®                                                             ele-                              Kenics.sup.®                             ments. No syrup                   elements.                                    fragments after                                                                16 Kenics.sup.®                                                            elements. Occa-                                                                sional water glob-                                                             ules after 16                                                                  Kenics.sup.®                                                               elements.                    2-8-3                                                                               Four plates (20)    9.1   (46.0)  17         Less channeling,                  with 61 0.07"                                                                              1046          22                 less pulsing,                     dia. holes in                                smaller scale non-                each +  16                                   uniformities than                 Kenics.sup.®                             those in Test                     elements.                                    1a-8-3. 1/32"                                                                  syrup fragments                                                                after 16                                                                       Kenics.sup.®                                                               elements.                                                                      No globules.                 1c-8-3                                                                              Same as     (20)    4.5   (26.6)  9          No pulsing above                  1a-8-3      1046          60                 4th plate. Stria-                                                              tions but no syrup                                                             fragments after 16th                                                           Kenics.sup.®                                                               element.                                                                       No water globules                                                              after 16th element.          1-8-25                                                                              Three per-  (20)    11.5  (48.8)  17         Good water distri-                forated     1046          --                 bution across whole of            plates, 4"                                   of first 2" plate.                separation,                                  1/4" water layer on               241 0.07"                                    1st plate, 1/8" on                holes in each                                2d, none on 3d. No                (FIG. 4), 2" dia.                            water pulsing above               tubing + 16                                  2d plate. 1/32"                   Kenics.sup.®  elements                   syrup fragments and               in 1" pipe.                                                                                                                 Kenics.sup.®                                                               elements.                    1-9-27                                                                              Four 43 hole                                                                               (20)    7.1   (26.2)  36         Relatively uniform                (0.07" dia)               --                 water distribution                plates, spaced                               past plates, without              2" apart,                                    pulsing above any                 followed by                                  plate. No channel-                16 Kenics®                               ing in                                                                         Kenics.sup.®                  elements.                                    elements. A few                                                                1/16"-1/8" syrup                                                               fragments after 16                                                             elements.                    2-9-27                                                                              Same as Test                                                                               (20)    6.8   (27.3)  24         Some maldistribu-                 1-9-27 except                                                                              1046          --                 tion on 1st plate,                85 0.07" holes                               cleared up after 3d               used in all                                  plate. Many                       plates.                                      1/32-1/16" syrup                                                               fragments after 16th                                                           Kenics.sup.®                                                               element.                                                                       Syrup jets above 1st                                                           plate didn't                                                                   "snake" as much as                                                             those in Test                                                                  1-9-27.                      4-9-27                                                                              Four 85 hole                                                                               (20)    33.2  (25.1)  15         Pulsing through 3d                (0.07" dia) 1046          --                 plate. Plug flow                  plates followed                              between 1st 4 plates.             by 4 43 hole                                 Channeling between                (0.07" dia)                                  5th-8th plates and                plates, followed                             first 6                                                                        Kenics.sup.®                  by 4 Kenics.sup.®                        elements. Screens                 elements then A                              refined syrup frag-               70 mesh screen                               ments to smaller                  with elements +                              size. Many stria-                 screen repeated                              tions and some syrup              twice more and                               fragments after 16                terminated with                              elements.                         4 Kenics.sup.®                                                             elements.                                                                 5-9-27                                                                              Same as Test                                                                               (20)    42    (19.6)  --         No syrup fragments                4-9-27      1046)         --                 after 16                                                                       Kenics.sup.®                                                               elements, but many                                                             striations. Flow                                                               in elements was                                                                erratic, with some                                                             backflow due to                                                                settling syrup                                                                 agglomerates.                __________________________________________________________________________

Study of the recorded observations for Tests 3-6-30 and 1-7-3 in TABLE III shows that the addition of perforated plates interspersed between Kenics® mixing elements provided more complete mixing than Kenics® elements alone.

A similar improvement in performance was noted in Tests 2-7-3 and 2-7-11 relative to Test 2-6-30 at a lower water rate.

The mixing superiority of multiple perforated plates over a single perforated plate is shown by comparision of the results of Tests 2-7-5 and 1-7-5.

Smaller 0.070 inch dia. holes provided better mixing than 1/8 inch dia. holes. Occasionally, the last Kenics® element effluent would show a water globule(Test 1a-8-3) when the larger holes were used, but never when the smaller 0.070 inch holes were used (Test 2-8-3).

When screens were disposed after the 4th, 8th and 12th Kenics® elements, the syrup fragments were reduced to a smaller size (Test 4-9-27). Also, a higher ratio of water to corn syrup could be tolerated. as shown by Tests 1-10-10, 3-10-10 and 2-10-18. 

What is claimed is:
 1. A method of mixing a low viscosity liquid with a high viscosity liquid where the proportion of said low viscosity liquid to said high viscosity liquid is in the volumetric flow ratio range of about 0.01 to 0.2, and where the ratio of viscosities of said high viscosity liquid to said low viscosity liquid is in the range of about 4 × 10³ to about 10⁶ comprising introducing said low viscosity liquid under pressure into a flowing stream of said high viscosity liquid, thence flowing said liquids through a perforated plate establishing a multiplicity of wakes of said low viscosity liquid on the downstream side of said plate, and then impelling said low viscosity and said high viscosity liquids through a static mixing element.
 2. A method of mixing a low viscosity liquid with a high viscosity liquid according to claim 1 wherein a plurality of said perforated plates are interposed ahead of said static mixing element. 